Pressure control device with composite annular seal assembly

ABSTRACT

A pressure control device can include a housing assembly, a releasable assembly releasably secured relative to the housing assembly, the releasable assembly being configured to seal against a tubular string extending through the pressure control device, and an annular seal assembly that prevents flow through an annular gap formed radially between the housing assembly and the releasable assembly, the annular seal assembly comprising a resilient seal element bonded to a rigid support element. A method of securing a releasable assembly in a housing assembly of a pressure control device can include attaching an annular seal assembly to the releasable assembly, the annular seal assembly comprising a rigid support element bonded to a resilient seal element, and receiving the releasable assembly at least partially in the housing assembly, thereby sealingly engaging the resilient seal element with a seal bore in the housing assembly.

BACKGROUND

This disclosure relates generally to equipment utilized and operations performed in conjunction with a subterranean well and, in an example described below, more particularly provides a pressure control device and associated methods and systems.

A pressure control device may be used to isolate a well annulus from the atmosphere at or near surface, for example, in managed pressure drilling operations. In that case, the pressure control device seals off the annulus surrounding a drill string (such as, an annulus between the drill string and an outer tubular riser string) and, in some examples, annular seals that sealingly engage the drill string can rotate with the drill string.

Therefore, it will be appreciated that improvements are continually needed in the art of designing, constructing and utilizing pressure control devices. Such improvements may be useful in well operations other than managed pressure drilling operations, and suitably improved pressure control devices may be used to seal about well components other than drill strings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a representative partially cross-sectional view of an example of a well system and associated method which can embody principles of this disclosure.

FIG. 2 is a representative cross-sectional view of an example of a pressure control device that may be used in the FIG. 1 system and method, and which can embody the principles of this disclosure.

FIG. 3 is a representative detailed cross-sectional view of an example of an annular seal assembly in the FIG. 2 pressure control device.

FIGS. 4 & 5 are representative cross-sectional views of the annular seal assembly.

DETAILED DESCRIPTION

Representatively illustrated in FIG. 1 is a system 10 for use with a subterranean well, and an associated method, which can embody principles of this disclosure. However, it should be clearly understood that the system 10 and method are merely one example of an application of the principles of this disclosure in practice, and a wide variety of other examples are possible. Therefore, the scope of this disclosure is not limited at all to the details of the system 10 and method as described herein and/or depicted in the drawings.

In the system 10 as depicted in FIG. 1, a generally tubular riser string 12 extends between a water-based rig 14 and a lower marine riser package 16 above a subsea wellhead installation 18 (including, for example, various blowout preventers, hangers, fluid connections, etc.). However, in other examples, the principles of this disclosure could be practiced with a land-based rig, or with a riser-less installation.

In the FIG. 1 example, a tubular string 20 (such as, a jointed or continuous drill string, a coiled tubing string, etc.) extends through the riser string 12 and is used to drill a wellbore 22 into the earth. For this purpose, a drill bit 24 is connected at a lower or distal end of the tubular string 20.

The drill bit 24 may be rotated by rotating the tubular string 20 (for example, using a top drive or rotary table of the rig 14), and/or a drilling motor (not shown) may be connected in the tubular string 20 above the drill bit 24. However, the principles of this disclosure could be utilized in well operations other than drilling operations. Thus, it should be appreciated that the scope of this disclosure is not limited to any of the details of the tubular string 20 or wellbore 22 as depicted in the drawings or as described herein.

The riser string 12 depicted in FIG. 1 includes an outer riser housing assembly 26 connected in the riser string 12 below a tensioner ring 28 suspended from the rig 14. In other examples, the riser housing assembly 26 could be connected above the tensioner ring 28, or could be otherwise positioned (such as, in the wellhead installation 18 in a riser-less configuration). Thus, the scope of this disclosure is not limited to any particular details of the riser string 12 or riser housing assembly 26 as described herein or depicted in the drawings.

The riser housing assembly 26 includes a side port 30 that provides for fluid communication between a conduit 32 and an annulus 34 formed radially between the riser string 12 and the tubular string 20. In a typical drilling operation, drilling fluid can be circulated from the rig 14 downward through the tubular string 20, outward from the drill bit 24, upward through the annulus 34, and return to the rig 14 via the conduit 32.

As depicted in FIG. 1, a releasable assembly 40 is installed in the riser housing assembly 26. The releasable assembly 40 in this example is of the type known to those skilled in the art as a rotating control device. The releasable assembly 40 and the outer riser housing assembly 26 comprise a pressure control device 48.

However, the scope of this disclosure is not limited to installation or retrieval of any particular type of releasable assembly in the riser housing assembly 26. In other examples, the releasable assembly 40 could comprise a portion of a non-rotating pressure control device (e.g., having one or more non-rotating annular seals for engagement with the tubular string 20).

In the FIG. 1 example, the releasable assembly 40 includes one or more annular seals 42 that seal off the annulus 34 above the side port 30. In this example, the annular seals 42 are configured to sealingly engage an exterior of the tubular string 20. The annular seals 42 may be of a type known to those skilled in the art as “passive,” “active” or a combination of passive and active. The scope of this disclosure is not limited to use of any particular type of annular seal.

Rotation of the annular seals 42 relative to the riser housing assembly 26 is provided for by bearings 44 of the releasable assembly 40. The annular seals 42 and bearings 44 are releasably secured in the riser housing assembly 26 by a latch 46. The latch 46 permits the annular seals 42 and/or the bearings 44 to be installed in, or retrieved from, the riser housing assembly 26 when desired, for example, to service or replace the seals 42 and/or bearings 44.

Various components of the latch 46 may be part of, or integral to, the riser housing assembly 26, the releasable assembly 40, or a combination thereof. The scope of this disclosure is not limited to any particular location(s) or configuration of any components or combination of components of the latch 46.

Referring additionally now to FIG. 2, a more detailed cross-sectional view of an example of the pressure control device 48 is representatively illustrated. The pressure control device 48 is described below as it may be used in the system 10 and method of FIG. 1, but it should be clearly understood that the pressure control device may be used in a variety of different systems and methods, in keeping with the principles of this disclosure.

In the FIG. 2 example, the releasable assembly 40 includes two of the annular seals 42 for sealingly engaging the tubular string 20. The annular seals 42 are connected to, and rotate with, an inner barrel 50. In this manner, the annular seals 42 can rotate with the tubular string 20 while sealingly engaging the tubular string.

The inner barrel 50 is rotatably supported by the bearings 44 relative to an outer barrel 52. To secure the releasable assembly 40 to the housing assembly 26, a latch member 54 of the latch 46 is displaced radially inward into engagement with an annular recess 56 on the outer barrel 52. The latch 46 may be hydraulically, pneumatically, electrically or otherwise actuated to displace the latch member 54. To release the releasable assembly 40 for retrieval from the housing assembly 26, the latch 46 is actuated to displace the latch member 54 radially outward and disengaged from the recess 56.

In other examples, the latch 46 could be part of the releasable assembly 40, in which case the annular recess 56 could be formed in the housing assembly 26, and the latch member 54 could be displaced radially outward into engagement with the recess, in order to releasably secure the releasable assembly 40 to the housing assembly. Thus, the scope of this disclosure is not limited to any particular details of the latch 46, housing assembly 26 and releasable assembly 40 as described herein or depicted in the drawings.

An annular seal assembly 60 is carried on the releasable assembly 40 for sealing between the releasable assembly and the housing assembly 26. In this example, the annular seal assembly 60 is sealingly engaged about the releasable assembly 40 and, when the releasable assembly is installed in the housing assembly 26, the annular seal assembly is sealingly engaged in the housing assembly.

Referring additionally now to FIG. 3, a larger scale cross-sectional view of an example of the annular seal assembly 60 operatively positioned between the releasable assembly 40 and the housing assembly 26 in the pressure control device 48 is representatively illustrated. In this view, it may be seen that the annular seal assembly 60 seals off and prevents flow through an annular gap 62 formed radially between the releasable assembly 40 and the housing assembly 26.

In the FIG. 3 example, the annular seal assembly 60 includes an elastic or resilient annular seal element 64 adhered or bonded to an annular rigid support element 66. The annular seal assembly 60 is retained on the releasable assembly 40 by a protective retainer sleeve 68.

As depicted in FIG. 3, the seal element 64 is sealingly engaged with an external surface 70 on the releasable assembly 40 (in this example, on a component 52 a sealingly connected to the outer barrel 52). When the releasable assembly 40 is operatively installed in the housing assembly 26, the seal element 64 is also sealingly engaged with a seal bore 72 in the housing assembly 26 (in this example, the seal bore is positioned in a latch housing 74 for securing the latch 46 in the housing assembly).

Referring additionally now to FIGS. 4 & 5, cross-sectional views of the example of the annular seal assembly 60 are representatively illustrated, apart from the remainder of the pressure control device 48. In these views, details of the construction of this example of the annular seal assembly 60 may be more conveniently seen.

In the FIGS. 4 & 5 example, the seal element 64 may comprise an elastomer (such as, rubber, nitrile, buna-N, HNBR, a fluoroelastomer, etc.), or another suitable resilient sealing material, capable of sealingly engaging the external surface 70 of the releasable assembly 40 and the seal bore 72 in the housing assembly 26. In other examples, combinations of sealing materials, combinations of sealing and non-sealing materials, and non-resilient materials may be used in the seal element 64.

As depicted in FIGS. 4 & 5, the rigid support element 66 includes two annular-shaped components 66 a,b. In other examples, the rigid support element 66 could comprise a single component, or other numbers of components. Other numbers of seal elements 64 could also be provided. Thus, the scope of this disclosure is not limited to any particular details of the annular seal element 60 as described herein or depicted in the drawings.

The rigid support element 66 comprises a relatively rigid material (such as, steel, ductile iron, other metal alloys and metals, composites, rigid polymers, etc.). Since the components 66 a,b are bonded to the seal element 64, the components restrict radial displacement of the seal element. This prevents the seal element 64 from being dislodged from the releasable assembly 40 as it is being conveyed through the riser string 12 (see FIG. 1), and prevents fluid flow from washing the seal element off of the releasable assembly and otherwise causing flow damage to the seal element.

In one example technique for producing the annular seal assembly 60, the seal element 64 can be made of an HNBR material and the support element components 66 a,b can be made of an SAE 4130 steel alloy. The seal element 64 can be positioned between the support element components 66 a,b in a heated press, with a bonding agent applied between the seal element and each of the support element components. The press is closed and pressure is increased to shape the seal element 64. Increased temperature in the press cures the HNBR material and activates the bonding agent, so that the support element components 66 a,b are permanently bonded to the seal element 64.

As may be more conveniently viewed in FIG. 5, the seal element 64 has respective radially inward and outward sealing surfaces 64 a,b and axially opposing bonding surfaces 64 c,d. The radially inward sealing surface 64 a sealingly engages the external surface 70 on the releasable assembly 40 (see FIG. 3), the radially outward sealing surface 64 b sealingly engages the seal bore 72 in the housing assembly 26, the bonding surface 64 c is adhered or bonded to the support element component 66 a, and the bonding surface 64 d is adhered or bonded to the support element component 66 b.

Note that the sealing surface 64 a extends radially inward farther than each of the support element components 66 a,b, and the sealing surface 64 b extends radially outward farther than each of the support element components. This enables the seal element 64 sealing surfaces 64 a,b to sealingly contact the respective external surface 70 and seal bore 72, and to deflect axially prior to fully engaging the releasable assembly 40 into the housing assembly 26.

Although the seal element 64 is depicted in the drawings as being positioned axially between the support element components 66 a,b, the seal element could be otherwise positioned in other examples. The seal element 64 could be positioned, for example, in an annular groove or recess internal or external to the support element 66.

It may now be fully appreciated that the above disclosure provides to the art significant advancements to the art of constructing and utilizing pressure control devices with subterranean wells. In examples described above, the pressure control device 48 includes the annular seal assembly 60 that allows the releasable assembly 40 to be positioned and sealed in the housing assembly 26, with damage to or dislodgment of the seal assembly being prevented, or at least mitigated.

A pressure control device 48 for use with a subterranean well is provided to the art by the above disclosure. In one example, the pressure control device 48 can include a housing assembly 26, a releasable assembly 40 releasably secured relative to the housing assembly 26, the releasable assembly 40 being configured to seal against a tubular string 20 extending through the pressure control device 48, and an annular seal assembly 60 that prevents flow through an annular gap 62 formed radially between the housing assembly 26 and the releasable assembly 40. The annular seal assembly 60 comprises a resilient seal element 64 bonded to a rigid support element 66.

The resilient seal element 64 may comprise an elastomer. The resilient seal element 64 may sealingly engage each of the housing assembly 26 and the releasable assembly 40.

The rigid support element 66 may comprise at least two components 66 a,b. The resilient seal element 64 may be bonded to each of the components 66 a,b. The resilient seal element 64 may be bonded between the components 66 a,b.

The resilient seal element 64 may be annular shaped and comprise radially inward and radially outward sealing surfaces 64 a,b, and axially opposite bonding surfaces 64 c,d. The radially inward sealing surface 64 a may sealingly engage the releasable assembly 40, the radially outward sealing surface 64 b may sealingly engage the housing assembly 26, and the axially opposite bonding surfaces 64 c,d may be bonded to at least one component 66 a,b of the rigid support element 66.

The releasable assembly 40 may comprise an outer barrel 52, at least one seal 42 configured to sealingly engage the tubular string 20, and bearings 44 that rotatably support the seal 42 relative to the outer barrel 52.

A method of securing a releasable assembly 40 in a housing assembly 26 of a pressure control device 48 is also provided to the art by the above disclosure. In one example, the method can include: attaching an annular seal assembly 60 to the releasable assembly 40, the annular seal assembly 60 comprising a rigid support element 66 bonded to a resilient seal element 64; and receiving the releasable assembly 40 at least partially in the housing assembly 26, thereby sealingly engaging the resilient seal element 64 with a seal bore 72 in the housing assembly 26.

The attaching step can include sealingly engaging the resilient seal element 64 with the releasable assembly 40.

The receiving step can include sealing off an annular gap 62 between the releasable assembly 40 and the housing assembly 26.

The rigid support element 66 may restrict displacement of the resilient seal element 64 radially relative to the releasable assembly 40. The resilient seal element 64 may be bonded between at least two components 66 a,b of the rigid support element 66.

A system 10 for use with a subterranean well is also described above. In one example, the system 10 can include: a housing assembly 26 configured for connection as part of a riser string 12; a releasable assembly 40 releasably secured relative to the housing assembly 26; and an annular seal assembly 60 that prevents flow through an annular gap 62 between the releasable assembly 40 and the housing assembly 26. The annular seal assembly 60 comprises an annular seal element 64 adhered to a rigid support element 66, the annular seal element 64 extending farther radially outward than the rigid support element 66.

The annular seal element 64 may comprise an elastomer. The annular seal element 64 may sealingly engage a seal bore 72 in the housing assembly 26, the seal bore 72 being formed in a latch housing 74 for a latch 46 that releasably latches the releasable assembly 40 with the housing assembly 26.

The annular seal element 64 may sealingly engage the releasable assembly 40.

The rigid support element 66 may include multiple components 66 a,b. The annular seal element 64 may be bonded to each of the components 66 a,b.

The rigid support element 66 may include at least two components 66 a,b. The annular seal element 64 may be bonded between the components 66 a,b.

Although various examples have been described above, with each example having certain features, it should be understood that it is not necessary for a particular feature of one example to be used exclusively with that example. Instead, any of the features described above and/or depicted in the drawings can be combined with any of the examples, in addition to or in substitution for any of the other features of those examples. One example's features are not mutually exclusive to another example's features. Instead, the scope of this disclosure encompasses any combination of any of the features.

Although each example described above includes a certain combination of features, it should be understood that it is not necessary for all features of an example to be used. Instead, any of the features described above can be used, without any other particular feature or features also being used.

It should be understood that the various embodiments described herein may be utilized in various orientations, such as inclined, inverted, horizontal, vertical, etc., and in various configurations, without departing from the principles of this disclosure. The embodiments are described merely as examples of useful applications of the principles of the disclosure, which is not limited to any specific details of these embodiments.

In the above description of the representative examples, directional terms (such as “above,” “below,” “upper,” “lower,” “upward,” “downward,” etc.) are used for convenience in referring to the accompanying drawings. However, it should be clearly understood that the scope of this disclosure is not limited to any particular directions described herein.

The terms “including,” “includes,” “comprising,” “comprises,” and similar terms are used in a non-limiting sense in this specification. For example, if a system, method, apparatus, device, etc., is described as “including” a certain feature or element, the system, method, apparatus, device, etc., can include that feature or element, and can also include other features or elements. Similarly, the term “comprises” is considered to mean “comprises, but is not limited to.”

Of course, a person skilled in the art would, upon a careful consideration of the above description of representative embodiments of the disclosure, readily appreciate that many modifications, additions, substitutions, deletions, and other changes may be made to the specific embodiments, and such changes are contemplated by the principles of this disclosure. For example, structures disclosed as being separately formed can, in other examples, be integrally formed and vice versa. Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the invention being limited solely by the appended claims and their equivalents. 

What is claimed is:
 1. A pressure control device for use with a subterranean well, the pressure control device comprising: a housing assembly; a releasable assembly releasably secured relative to the housing assembly, the releasable assembly being configured to seal against a tubular string extending through the pressure control device; and an annular seal assembly that prevents flow through an annular gap formed radially between the housing assembly and the releasable assembly, the annular seal assembly comprising a resilient seal element bonded to a rigid support element.
 2. The pressure control device of claim 1, in which the resilient seal element comprises an elastomer.
 3. The pressure control device of claim 1, in which the resilient seal element sealingly engages each of the housing assembly and the releasable assembly.
 4. The pressure control device of claim 1, in which the rigid support element comprises at least two components, and the resilient seal element is bonded to each of the components.
 5. The pressure control device of claim 1, in which the rigid support element comprises at least two components, and the resilient seal element is bonded between the components.
 6. The pressure control device of claim 1, in which the resilient seal element is annular shaped and comprises radially inward and radially outward sealing surfaces, and axially opposite bonding surfaces, and in which the radially inward sealing surface sealingly engages the releasable assembly, the radially outward sealing surface sealingly engages the housing assembly, and the axially opposite bonding surfaces are bonded to at least one component of the rigid support element.
 7. The pressure control device of claim 1, in which the releasable assembly comprises an outer barrel, at least one seal configured to sealingly engage the tubular string, and bearings that rotatably support the seal relative to the outer barrel.
 8. A method of securing a releasable assembly in a housing assembly of a pressure control device, the method comprising: attaching an annular seal assembly to the releasable assembly, the annular seal assembly comprising a rigid support element bonded to a resilient seal element; and receiving the releasable assembly at least partially in the housing assembly, thereby sealingly engaging the resilient seal element with a seal bore in the housing assembly.
 9. The method of claim 8, in which the attaching comprises sealingly engaging the resilient seal element with the releasable assembly.
 10. The method of claim 8, in which the receiving comprises sealing off an annular gap between the releasable assembly and the housing assembly.
 11. The method of claim 8, in which the rigid support element restricts displacement of the resilient seal element radially relative to the releasable assembly.
 12. The method of claim 8, in which the resilient seal element is bonded between at least two components of the rigid support element.
 13. The method of claim 8, in which the rigid support element comprises at least two components, and in which the resilient seal element is bonded to each of the components.
 14. The method of claim 8, in which the releasable assembly comprises an outer barrel, at least one seal configured to sealingly engage the tubular string, and bearings that rotatably support the seal relative to the outer barrel.
 15. A system for use with a subterranean well, the system comprising: a housing assembly configured for connection as part of a riser string; a releasable assembly releasably secured relative to the housing assembly; and an annular seal assembly that prevents flow through an annular gap between the releasable assembly and the housing assembly, the annular seal assembly comprising an annular seal element adhered to a rigid support element, the annular seal element extending farther radially outward than the rigid support element.
 16. The system of claim 15, in which the annular seal element comprises an elastomer.
 17. The system of claim 15, in which the annular seal element sealingly engages a seal bore in the housing assembly, the seal bore being formed in a latch housing for a latch that releasably latches the releasable assembly with the housing assembly.
 18. The system of claim 15, in which the annular seal element sealingly engages the releasable assembly.
 19. The system of claim 15, in which the rigid support element comprises multiple components, and in which the annular seal element is bonded to each of the components.
 20. The system of claim 15, in which the rigid support element comprises at least two components, and in which the annular seal element is bonded between the components. 